Caterpillar Cat C9.3 Industrial Engine (Prefix CS9) Service Repair Manual Instant Download

Service Repair Manual
Models
C9.3 Industrial Engine

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Product: INDUSTRIAL ENGINE

Model: C9.3 INDUSTRIAL ENGINE CS9
Configuration: C9.3 Industrial Engine CS900001-UP
Disassembly and Assembly

Media Number -UENR0183-02 Publication Date -01/06/2014 Date Updated -06/06/2014
i05834261
Unit Injector - Remove and Install

SMCS - 1290-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 268-1968 Pry Bar 1
B - Scotch Brite 1
1U-5718 Vacuum Pump 1
169-7372 Bottle Assembly 1
Clear Plastic Tubing
C 4C-4057 1
7.92 mm (0.312 inch) OD
Clear Plastic Tubing
4C-4055
6.35 mm (0.250 inch) OD
D 9U-5470 Reamer 1
E 4C-6161 Tube Brush 1
F 9U-6862 Tapered Brush 1
G 4C-6774 Vacuum Gun Kit 1
H 4C-5027 Tap Wrench 1
Start By:
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A. Remove the valve mechanism cover.

B. Remove the fuel injection line.
C. Remove Compression Brake (If Equipped).
Illustration 1 g01264292
Note: Do not remove the quill tube. This action will reduce the risk of contamination to the
system.
1. Fully loosen quill tube nut (1) . Pull quill tube (1) out of the bore until you see O-ring seal
(2) . This action will ensure that the injector does not contact the quill tube during removal.
At this time, inspect O-ring seal (2) for wear or for damage. Replace the O-ring seal if
necessary.
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Typical Example
2. Disconnect harness assembly (3) from the unit injector.
Typical Example
3. Remove bolt (5) from clamp (6) .
Note: When possible, remove the unit injector by hand by twisting the unit injector and
pulling upward. Be sure not to strike the unit injector during the removal procedure.
4. If unit injector (4) cannot be removed by hand, go to Step 5.
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Typical Example
Note: Do not damage the unit injector during removal. Side loading may damage to the unit
injector.
5. Position Tooling (A) under unit injector clamp (6) . Carefully remove unit injector (4) from
the cylinder head.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Evacuate as much fuel and oil as possible from the cylinder head before installing the unit
injector. Several evacuations may be necessary. Use Tooling (C) to remove the fuel and oil
from the cylinder.
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Note: Tooling (F) is available to clean loose material from the sleeve bore and the cylinder.
2. Clean the carbon from the sleeve, the sleeve bore, and the end of the unit injector. Clean the
carbon from the seat area that is inside of the cylinder head. A fine grade of Tooling (B) is
preferred. Clean the carbon from the cylinder head. If the sleeve of the unit injector has been
removed, use Tooling (D) to remove only carbon from the surface of the sleeve. If the
sleeve of the unit injector is installed, use Tooling (E) to clean the carbon deposit from the
inside of the sleeve.
The following procedure is the preferred method of cleaning the sleeve bore.
Place a 38 mm (1.5 inch) square piece of Scotch Brite material on the end of Tooling (F) .
Twist Tooling (F) with Tooling (H) against the lower surface of the sleeve bore.
The surface should be cleaned until the surface is smooth and shiny. The entire sleeve bore
should be cleaned in order to remove any loose carbon particles.
Note: Tooling (G) is available to clean loose material from the sleeve bore and the cylinder.
NOTICE
The correct procedures and tooling specifications must always be used.

Failure to follow any of the procedures may result in damage,
malfunction, or possible engine failure.
Note: Replace the O-ring seals on the injector.
3. Install O-ring seal (9) and O-ring seal (10) on unit injector (4) . Lubricate O-ring seal (9) , O
-ring seal (10) , and the sleeve bore of the unit injector sparingly with clean engine oil.
4. Record the serial number for the injector and the injector confirmation code. When you
install a new unit injector, the E-Trim value must be programmed into the Engine Control
Module. For more information, refer to Troubleshooting, "Injector Trim File - Install".
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Note: Verify quill tube (1) is positioned out of the bore enough to see O-ring seal (2) . This
action will ensure that the injector does not contact the quill tube during installation.
5. Place unit injector (4) into the bore. Make sure that the key (7) for the unit injector fits into
slot (8) in the cylinder head.
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Note: Use new socket head bolt (5) .
6. Position unit injector clamp (6) with the label "C9" in the up position. Install socket head
bolt (5) into unit injector clamp (6) . Tighten socket head bolt (5) to a torque of 28 ± 3 N·m
(21 ± 2 lb ft) in order to secure unit injector (4) .
7. Connect harness assembly (3) to the unit injector.
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Note: Check the O-ring seal for wear or for damage. If necessary, replace the O-ring seal.
8. If the O-ring seal was damaged, perform Step 8.a and Step 8.b.
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a. Inspect the Sealing Surface (A) for damage. Replace quill tube (1) if damage was
found.
b. Lubricate new O-ring seal (2) with clean engine oil. Install new O-ring seal (2) .
9. Lubricate the O-ring seal, the nut face, and the threads with clean engine oil. Insert quill
tube (1) into the bore with the ball on the right side. Once the quill tube has bottomed out,
rotate the quill tube until the ball engages with the slot. The quill tube should drop slightly
when the ball is engaged with the slot. This action will install quill tube (1) . Ensure that the
ball is in alignment with the slot for quill tube (1) . Tighten the nut for quill tube (1) to a
torque of 70 ± 3 N·m (52 ± 2 lb ft).
End By:
a. Install Compression Brake (If Equipped).

b. Install the valve mechanism cover.
c. Install the fuel injection line.
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i05282771
Unit Injector Sleeve - Remove and Install

SMCS - 1713-010
Removal Procedure
Table 1
Required Tools
A - Tap 7/8-9 NC 1
1A-5576 Bolt 1
B
8C-6913 Hard Washer 7
C 221-9803 Rubber Stopper 1
D 1P-0510 Driver Gp 1
E 4C-5552 Large Bore Brush 1
F 4C-9507 Retaining Compound 1
Start By:
a. Remove the unit injectors.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
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NOTICE
Care must be taken to ensure that fluids are contained during

performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain fluids on
Cat® products.
Dispose of all fluids according to local regulations and mandates.
1. Drain the coolant from the cooling system into a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual, "Refill Capacities and Recommendations".
2. Position Tooling (C) at the bottom of the unit injector sleeve (1).
3. Coat Tooling (A) (not shown) with clean grease. Use Tooling (A) to cut threads into unit
injector sleeve (1).
4. Use Tooling (B) in order to remove unit injector sleeve (1). Discard the unit injector sleeve
(1).
1. Thoroughly clean the bores for the unit injectors with Tooling (E).
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2. Apply clean engine oil to O-ring seals (2). Install O-ring seals (2) on unit injector sleeve (1).
3. Apply a thin coating of Tooling (F) around the outer circumference of unit injector sleeve
(1) at Area (G).
4. Position unit injector sleeve (1) in the cylinder head. Use a hammer and Tooling (D) in
order to install unit injector sleeve (1) in the cylinder head.
Note: Allow Tooling (F) to cure for 2 hours at 21 °C (70 °F) before filling the engine with
fuel or coolant. Longer curing time is required for lower temperatures.
5. Fill the cooling system with coolant to the correct level. Refer to Operation and
Maintenance Manual, "Refill Capacities and Recommendations".
End By:
a. Install the unit injectors.
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i05831969
Turbocharger - Remove and Install - Cooled by Coolant

SMCS - 1052-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description QTY
A - Loctite C5A Copper Anti-Seize 1
1. Drain the cooling system into a suitable container for storage or disposal. Refer to Operation
and Maintenance Manual, "Cooling System Coolant (ELC) - Change".
2. Disconnect tube assemblies (1) and (2) .
3. Disconnect hose (3) .
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4. Disconnect hose assemblies (4) and (5) .
5. Remove four nuts (7) and remove turbocharger (6) . Discard nuts (7) and remove the gasket.
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Note: Band clamps (8) , (9) and (10) , are one time use parts. Discard the clamp assemblies
if the clamps are loosened.
6. Remove band clamp (8) in order to separate the adaptor from the turbine housing. Discard
band clamp (8) .
7. Remove band clamp (9) in order to separate the turbine housing from the cartridge
assembly. Discard band clamp (9) .
8. Remove band clamp (10) in order to separate the compressor housing from the cartridge
assembly. Discard band clamp (10) .
9. Remove adapters (11) from the cartridge assembly.
Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the
components, if necessary.
1. Install the turbocharger (6) in the reverse order of removal.
a. Install new band clamp (9) . Tighten band clamp (9) to a torque of 18 N·m (159 lb in).
Loosen band clamp (9) and retighten the clamp to a torque of 13.6 ± 1.2 N·m (120 ±
11 lb in).
b. Install new band clamp (10) . Tighten band clamp (10) to a torque of 13.6 ± 1.2 N·m
(120 ± 11 lb in).
c. Install new band clamp (8) . Tighten band clamp (8) to a torque of 12 ± 4 N·m (106 ±
35 lb in).
d. Apply Tooling (A) to the threads of new nuts (7) prior to installation.
e. Tighten nuts (7) to a torque of 70 ± 5 N·m (52 ± 4 lb ft).
f. Put clean engine oil in the oil inlet of the turbocharger after assembly or before
installation. This action will provide lubrication during start-up and during storage.
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i03907730
Solenoid Valve (Exhaust Balance) - Remove and Install

SMCS - 1052-010-VL
Removal Procedure
1. Disconnect harness assembly (2). Disconnect tube assemblies (1) and (3).
2. Remove solenoid balance valve (4).
1. Install the solenoid balance valve (4) in the reverse order.
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i05295284
Air Control Valve - Remove and Install

SMCS - 108A-010
Removal Procedure
View of the Air Control Valve which is located on the Clean Emissions Module.
1. Remove cable straps (2). Disconnect harness assemblies (1) and position the harness
assembly out of the way.
2. Remove tube assembly (3).
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3. Loosen clamp assembly (5). Remove bolts (4) and remove air control valve (6).
4. Remove bolts (11). Separate housings (10) and (7) from the air control valve actuator (8).
Remove both seals (9) from the housings.
1. Install air control valve (8) in the reverse order of removal.
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i05295410
Exhaust Cooler (NRS) - Remove and Install

SMCS - 1087; 108C-010
Removal Procedure
Table 1
Required Tools
207-1600(1) Rubber Lubricant 1
A
207-1601 Rubber Lubricant 1
(1)
For Use in EAME
Note: Due to various machine configurations, components will need to be removed that are not
called out in this procedure. Refer to the appropriate manual to remove the necessary components.
1. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the
proper draining and filling procedures.
Note: Step 2 through Step 4 may not apply to all engine configurations. If so, then start with
Step 5.
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2. Disconnect hose assembly (2).
3. Remove hose (1), hose (3), the adapters, and the clips.
4. Position oil level gauge (4) out of the way. Remove bracket assembly (5).
5. Loosen band clamps (6) and the hose.
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Note: The band clamps and hose are one-time use components. Discard upon removal and
install new.
6. Loosen clamps (10). Remove bolts (8) and (11).
7. Remove exhaust cooler (7). Remove bellows (9) and clamps (10) from exhaust cooler (7).
Note: Note the orientation of the bellows. The arrow should point toward the exhaust
cooler.
8. Remove tubes (12). Remove the O-ring seals from tubes (12).
1. Install exhaust cooler (7) in the reverse order of removal.
a. Apply a light coating of Tooling (A) to the bores and the O-ring seals for tubes (12).
b. Install new bellows (9) and clamps (10). Tighten clamp assemblies (10) to a torque of
7.5 ± 1 N·m (66 ± 9 lb in).
Note: The arrow on the bellows should point toward the exhaust cooler. Total
misalignment for the bellows is 1.50 mm (0.06 inch) lateral and 1.50 mm (0.06 inch)
axial.
c. Tighten bolts (11) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
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i05295411
Exhaust Gas Valve (NRS) - Remove and Install

SMCS - 108N-010; 5510
Removal Procedure
1. Disconnect clamp assembly (1). Disconnect harness assemblies (2) and disconnect hose
assemblies (4). Disconnect clamp assembly (3).
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2. Remove four bolts (5) and remove exhaust gas valve (6).
1. Install exhaust gas valve (6) in reverse order of removal.
a. Tighten clamp assembly (3) to a torque of 8.5 ± 2 N·m (75 ± 18 lb in).
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i03513485
Exhaust Gas Valve (NRS) - Disassemble

SMCS - 108N-015; 5510
Disassembly Procedure
Start By:
a. Remove the Exhaust Gas Valve.
1. Remove temperature sensor (1).
2. Remove bolts (2). Separate actuator assembly (3) from the valve housing (4).
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Service Repair Manual

C9.3 Industrial Engine

Product: INDUSTRIAL ENGINE

Disassembly and Assembly

Unit Injector - Remove and Install

A. Remove the valve mechanism cover.

Hello dear friend!

2. Disconnect harness assembly (3) from the unit injector.

3. Remove bolt (5) from clamp (6) .

4. If unit injector (4) cannot be removed by hand, go to Step 5.

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

The correct procedures and tooling specifications must always be used.

Note: Replace the O-ring seals on the injector.

Note: Use new socket head bolt (5) .

7. Connect harness assembly (3) to the unit injector.

a. Install Compression Brake (If Equipped).

Product: INDUSTRIAL ENGINE

Disassembly and Assembly

Unit Injector Sleeve - Remove and Install

a. Remove the unit injectors.

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Care must be taken to ensure that fluids are contained during

Refer to Special Publication, NENG2500, "Dealer Service Tool

Dispose of all fluids according to local regulations and mandates.

a. Install the unit injectors.

Product: INDUSTRIAL ENGINE

Disassembly and Assembly

Turbocharger - Remove and Install - Cooled by Coolant

2. Disconnect tube assemblies (1) and (2) .

3. Disconnect hose (3) .

4. Disconnect hose assemblies (4) and (5) .

9. Remove adapters (11) from the cartridge assembly.

1. Install the turbocharger (6) in the reverse order of removal.

e. Tighten nuts (7) to a torque of 70 ± 5 N·m (52 ± 4 lb ft).

Product: INDUSTRIAL ENGINE

Disassembly and Assembly

Solenoid Valve (Exhaust Balance) - Remove and Install

2. Remove solenoid balance valve (4).

Product: INDUSTRIAL ENGINE

Disassembly and Assembly

Air Control Valve - Remove and Install

2. Remove tube assembly (3).

Product: INDUSTRIAL ENGINE

Disassembly and Assembly

Exhaust Cooler (NRS) - Remove and Install

2. Disconnect hose assembly (2).

5. Loosen band clamps (6) and the hose.

6. Loosen clamps (10). Remove bolts (8) and (11).

c. Tighten bolts (11) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

Product: INDUSTRIAL ENGINE

Disassembly and Assembly

Exhaust Gas Valve (NRS) - Remove and Install

a. Tighten clamp assembly (3) to a torque of 8.5 ± 2 N·m (75 ± 18 lb in).

Product: INDUSTRIAL ENGINE

Disassembly and Assembly

Exhaust Gas Valve (NRS) - Disassemble